Container



Oct. 31, 1961 E. P. HERRMANN CONTAINER 2 Sheets-Sheet 1 Filed Oct. 11,1957 ENVENTOR EDMUND Pf/E/FFMAN/V BY 241 4 firm fw M ATTORNEY5 Oct. 31,1961 E. P. HERRMANN CONTAINER 2 Sheets-Sheet 2 Filed Oct. 11, 1957 FIG.2.

FIG. 3

INVENTOR EDMUND P f/Efi/PMANA/ United States Patent 3,006,525 CONTAINEREdmund P. Hermann, Glen Ridge, N.J., assignor to Hudson Pulp & PaperCorporation, New York, N.Y., a corporation of Maine Filed Oct. 11, 1957,Ser. No. 689,511 8 Claims. (Cl. 229-17) This invention relates to liquidtight paperboard containers, and more particularly to containers madeentirely from a single paperboard blank; such containers being suitablefor the packaging, storing, shipping and selling of liquids such asmilk.

Prior to the present invention liquid tight containers of the paperboardtype (or as they are sometimes called the fibre type) have generallybeen made of many separate component pieces. Heretofore, severalassembly and/or sub-assembly operations were required to produce thecompleted container. While these multi-component containers have beensatisfactory from a utility standpoint they have been more expensive tomanufacture than a container made primarily from a single blank.

Containers of this general single blank type have been suggestedpreviously, but all have suffered from various shortcomings. Some of thesuggested containers have had gabled or wedge-shaped tops, and were notcapable of being stacked upright one upon another, for example, in astorage refrigerator.

Other prior one piece containers have required the use of prominent andprojecting flanges or ledges at the upper edges, and they areparticularly susceptible to damage. Also, the upper portion of such acontainer must necessarily be tapered in order to permit the forming ofthe flanges and still not have them extend beyond the crosssectionalarea of the container body. Because of this tapering the container mustbe either taller or of greater cross-sectional area at the base thanwould be the case if it had a uniform cross-section, and consequently itmust occupy greater shipping and storage space.

Some multi-component containers, such as that used for packaging milk,have uniform cross-sectional areas, and a top pouring opening fittedwith a hinged, single-ply plug piece attached by a wire staple. Thisplug portion has a pocket or recess which becomes filled withcontaminated water or dirt during handling or storage. If there is eventhe slightest perforation in the bottom of the plug wall the Water ordirt will seep into the container and contaminate the contents.

It is an object of this invention to provide an inexpensive paperboardcontainer, capable of being economically Patented Oct. 31, 1961 iceadapt it in numerous forms, each as may be best suited to therequirements of the particular usage.

In the drawings:

FIGURE 1 is a plan view on a reduced scale of a blank from which acomplete container may be made;

FIGURE 2. is a side elevation of an assembled container;

FIGURE 3 is an enlarged fragmentary perspective view of the top of anassembledcontainer with the top closed and sealed; and

FIGURE 4 is an enlarged fragmentary perspective view of the top of anassembled container with the top tear strip and the underlying plugportion pulled away.

In FIGURE 1 of the drawings, a blank 10 is shown which is capable ofbeing formed into a complete liquid tight container 11 illustrated inFIGURE 2. The blank 10 is divided primarily into panels and flaps byscore lines. Score lines 12 divide the body of the blank into four sidepanels, 14, 16, 1'8 and 20, and a connecting side flap 22. Other scorelines 24- define bottom end flaps 26, 28, 30 and 32 extending frompanels 14, 16, 18 and 20 respectively; and score lines 34 define the topend flaps 36, 38, 40 and 42, extending from panels 14, 16, 1S and 20,respectively. Score line 34 also divides a tab portion 44 extending fromthe end of the connecting flap 22.

The bottom end flaps are separated from adjacent end fiaps by cut lines46. The cut lines46 have angle extensions 47 adjacent score lines 24,which define web portions 48 adjacent the points where the cut lines 46would normally meet the score lines 24, if the out line extended in astraight line. A similar web portion 50 is provided joining flaps 22 and32. These web portions reinforce the bottom corners when the blank hasbeen formed into a container. The top end flaps 38, 40 and 42 areseparated from each other by cut lines 52, and flap 36 is separated fromflap 38 by a jogged out line 54.

A round aperture 56 is provided in flap 38, and a similar but, slightlysmaller aperture 58 is provided in fiap 40. These apertures areeccentrically located with respect to the centers of their respectiveflaps, each between the center and a corner of its flap. In forming theblank 10 manufactured from a one piece blank with a minimum ofoperations.

It is another object to provide a multi-ply top which is strong andsubstantially free of pockets or recesses. It is a further object toprovide a container with a multiply bottom which does not tend to bulgeand round on the bottom when filled.

It is still another object to provide a container which may be sealed atthe top, and then filled through the bottom in an upside-down positionbefore the bottom is into a container 11, the apertures are brought intoconcentric registration with flap 40 overlying flap 38, so that theyform a reinforced pouring opening positioned adjacent one corner of thecontainer top.

In the illustrative embodiment of the invention, flap 42 is divided bypartially cut or weakened lines 60 to define a tear strip portion orarea 62 the center of which is formed into a plug portion 64 (see FIGURE2) during the assembly or container-forming operation. The plug portion64 fits into the registered apertures 56 and 58 in the completedcontainer, with flap 42 overlying flap 40. A group of scored or weakenedlines 66 and a cut line 68 at the end of the strip 62 serve as hingemeans for the plug portion 64 when it is extracted from the apertures.

As indicated above, aperture 56 in flap 38 is slightly larger indiameter than aperture 58 in flap 40. The greater sized aperture 56provides an inwardly flaring double wall opening with the pouring edgebeing of single wall thickness. This arrangement also facilitatesmanufacture of the container because it provides a margin inregistration of the apertures. Flap 36 is also divided by a pair of cutor weakened lines or perforation lines 70 to provide a tear strip 72.The-tear strip 72 has integral lift tabs 74 and 76 and a connecting tab78 which are defined by score lines 80 and 82 and a out line 84. A groupof weakened lines 86 serve as hinge means for tear strip 72 when it islifted away from flap 36.

In order to join the various portions of the blank 10 together to formthe completed container 11 shown in FIGURE 2, the blank 10 isselectively coated, illustra- V patible with the previously appliedplastic coating.

tively as indicated by shading in FIGURE 1, over areas and lines with asuitable thermoplastic adhesive. Connecting flap 22, end flap 38, tabportion 44, web 5%) and connecting tab 78 are coated with the adhesivesubstantially throughout their entire top surfaces. Bottom flaps 28, 30and 32 are coated at their peripheries along strips 90 and also on theircenter areas 92. Top flap 40 is adhesively coat-ed except for asubstantial area 94 about aperture 58. Flap 42 is also coated except inan area at the edges of the tear strip or area 62. Adhesive lines 96 areprovided in the area 94 to provide tacking means for holding the plugarea 62 in position when plug 64 is inserted into apertures 56 and 58.Lift tabs 74 and 76 have adhesive lines 98 on their under sides and theupper surface of tab 78 is completely coated all for securing the tabsin folded position in the formed container as shown in FIGURES 2 and 3.

The first step in making a container of the illustrated type is to cutand score the blank 10. This is carried out on a press which may also beadapted to print the labeling on the container. The blank is then coatedwith a suitable plastic coating to seal the edges and cut portions,making the blank substantial liquid proof and sealed against wicking.The blank is next coated or printed throughout the shaded areas ofFIGURE 1, as discussed above, with a suitable adhesive which is com- Inthis prepared and flat condition, the blank may be shipped to thepackaging place-such as a dairywhere it is formed into a container,filled and sealed. If it is not economical for the packer to form theblanks into containers, they may be worked further at the blankmanufacturing site, and shipped in partially or fully assembledcondition in dustproof bags or cartons.

In the forming or assembling step the prepared blank is fed into aforming machine of the box-making type. The blank is wrapped about amandrel by folding the side panels 14, 16, 18 and 20 and the connectingflap 22 along the score lines 12. Panel 14 is wrapped over flap 22 andadhesively joined thereto by activating the adhesive on the flap bymeans of a heated strip located in that portion of the mandrel adjacentthe flap. The heated strip is heated only sufliciently to flow thethermoplastic adhesive on flap 22.

With the body of the container formed, the top end flaps 36, 38, 40, 42are next set in flace. Flap 38 is folded along score line 34 andpositioned against the head of the wrapping mandrel. Tab 44 is foldednext and then flap 40 is placed against the mandrel and the apertures 56and 58 set in registered position, and they are positioned adjacent arecess or female opening in the mandrel. Then flap 42 folded over sothat the plug area 62 overlies the registered apertures 56 and 58. Thefemale die opening in the mandrel conforms to the shape of the desiredplug, and a mating male punch die with an expandable head is projectedagainst the plug area 62. The punch die projects the plug materialthrough the apertures 56 and 58 and the end of the punch die expands andextrudes the plug portion into the female die opening. Hence, theplug 64is formed in place, and then the punch die is retracted. Flap 36 then isfolded and the lift tabs 74 and 76 set in place against panels 18 and16. The assembled top is then sealed by heating the previously appliedthermoplastic adhesive to a flow condition and pressing the severalflaps into liquid tight relationship. a

If the container has been assembled at the packing or filling place, itmay be then filled immediately and the end flaps sealed over. However,if the container is only assembled and not filled at the blankmanufacturing site the end flaps 26, 28, 30 and 32 may be folded overand tacked in holding contact to prevent contamination of the interiorof the container during shipment. This may be accomplished by applying athin overcoating of a compatible thermoplastic adhesive to the adhesivearea 92 of flap 30. This overcoating preferably has a lower flowtemperature than the permanent adhesive. Flap 30 is provided with theextra coating as it is folded the next to the last in forming the bottomand will hold the underlying flaps 32 and 28 and the overlying flap 26in place.

If it is desired to coat the container with a coating of parafin waxinstead of plastic, the container need not be coated until after the tophas been scaled. It is then immersed completely in a bath of moltenparaflin, removed, drained and cooled rapidly by refrigeration. The flowtemperature of the parffin wax is lower than that of the adhesive sothat it flows before the adhesive thus providing good adhesive contact.

When the container is to be filled, the contents are placed into itthrough the open bottom. By bottom filling the container, the tightlysealed top need not be disturbed until the container reaches the finaluser. After the container has been filled it is ready to have the bottomsealed liquid tight.

The bottom is sealed by slightly indenting the bottoms of the side wallsof the container with horizontal slide members or any other suitableclamping and crimping means. The slide members form a bottom flange orledge 100 and an obtusely angled bottom panel area 102 in each sidepanel as shown in FIGURE 2. After the panel area 102 has been formed andthe bottom flaps folded in the sequential order of 32, 28, 30 and 26, aheated platen is pressed against the upside-down bottom.

The slide members are preferably kept in engagement with the containerduring the application of the platen. By so doing, the platen has asuitable bearing surface to press against and the adhesive strips 99 arecaused to flow sufliciently to seal the flaps together at theirperipheries and center to form a liquid-tight bottom.

In forming the bottom, the end flaps may be forced into a concavecondition as shown in FIGURE 2. The concave bottom has the advantage ofresisting rounding out. Single-ply bottom containers often round outafter filling and the slightest protrudence on the surface beneath thesingle ply bottom may cause a leak. Th container in the illustratedembodiment in FIGURE 2 does not have that fault.

After the container has been filled and the bottom sealed, it may besprayed with another plastic coat if desired as a further seal. However,such a coating is not normally required. If any leaks were to developthey would normally occur at the corner points where the bottom flapsare joined to the side panels. This danger is reduced by the use of theweb portions 48 and 50.

In FIGURES 2 and 3, the closed flat container top is shown free ofoutstanding ledges or flanges which might be easily damaged in handling.In FIGURE 4 the top is shown in an open position. To open the containerthe tear strip 72 is raised upwardly about tthe hinge lines 86. The lifttabs 74 and 76 provide convenient access means for lifting the strip 72.Since the tear strip or plug area 62 is adhesively secured to the tearstrip 72,

the plug 64 is also lifted out of the apertures 56 and 58 forming thepouring opening when the tear strip is pulled upwardly.

The hinged plug 64 may be easily reinserted into the pouring openingafter each use.

It may be desirable to use a separate plug member in place of formingthe plug portion 64 in the plug area 62. In such a case the plug area 62must be provided with an opening suflicient to accommodate the separateplug. If a separate plug is used it should be provided with a flangesufiiciently large enough to permit it to be secured to the tear strip72.

The above described embodiment and the method of manufacture are merelyillustrative of the present invention and are set forth to provide afull understanding of this invention and its many benefits andadvantages. To those gifted in the art, modifications will occur whichwill come within the scope and spirit of the present invention asdefined in the following claims:

I claim:

1. A tubular paperboard container for liquid comprising a body portionformed of integrally joined side panels in angular relation, a bottomportion integrally joined in watertight relation with the lower end ofsaid body portion, a top portion including four top flaps extending fromsaid side panels, the first and second lower-most of said top flaps eachhaving an aperture therein and being positioned whereby said aperturesare in registry, the third of said folded top flaps having a plugportion formed from said flap integral therewith and fitting securelyinto said registered apertures, and an uppermost flat top flap having atear strip overlying and secured to said plug portion whereby the plugportion is removed from the apertures when the tear strip is torn andlifted upwardly.

2. A tubular paperboard container as defined in claim 1, wherein each ofsaid side panels ad its respective integral top flap are foldably joinedin angular relation, each fold line being substantially along a'peripheral line of said uppermost flat top flap.

3. A tubular paperboard container as defined in claim 1 wherein saiduppermost fiat top flap has an integral lift tab extending from saidtear strip portion thereof, sai lift tab being folded and detachablysecured to one of said side panels and constituting means for liftingsaid tear strip.

4. A tubular paperboard container as defined in claim 1 wherein saidbottom portion comprises bottom flaps extending from said side panelssaid flaps being folded, closed together and sealed, said bottom beingwatertight.

5. A tubular paperboard container as defined in claim 1 wherein saidbottom comprises bottom flaps extending from said side panels, saidflaps being folded and sealed together to form a concave bottom.

6. A tubular paperboard container as defined in claim 1 wherein the areaof the aperture in said first folded top flap is greater than the areaof the aperture in said secand folded top flap and the side of the plugis flared outwardly along the sloping :line formed by the walls of theaperture whereby the apertures and the plug are interlocked.

7. A tubuiar paperboard container as defined in claim 6, wherein each ofsaid top flaps is secured in substantially right angular relationshipwith its respective integral side panel.

8. A tubular paperboard container for liquid comprising a body portionformed of integrally joined side panels in angular relation, a bottomportion comprising bottom flaps extending from said side panels, sideflaps being folded and sealed together to form a concave liquid tightbottom, a top portion including top flaps extending from said sidepanels, first and second of said top flaps each having an aperturetherein and being folded whereby said apeitures are in registeredposition, an intermediate folded top flap having a severable plugportion in tegral therewith and fitting securely into said registeredapertures, and an uppermost fiat top flap having a tear strip overlyingand secured to said plug portion whereby the plug portion is removedfrom the apertures when the tear strip is lifted upwardly, said finaltop flap having at least one lift tab being folded and detachablysecured to one of said side panels whereby means is provided for liftingsaid tear strip and the accompanying plug portion upwardly.

References Cited in the file of this patent UNITED STATES PATENTS2,002,363 Daller May 21, 1935 2,020,680 Forrer Nov. 12, 1935 2,232,088Waters Feb. 18, 1941 2,272,203 Hothersall Feb. 10, 1942 2,435,155 PalmerJan. 27, 1948 2,570,266 Nordquist Oct. 9, 1951 2,657,848 Norden Nov. 3,1953 2,775,388 Nerenberg Dec. 25, 1956

